Additive Precursor Machining for Multiple Discrete Objects

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Solution Overview

Problem

Subtractive manufacturing processes are labor-intensive and limited in geometry due to the need to load and unload individual bodies of material, and they struggle with efficiently producing multiple discrete objects from a single block of material.

Innovation Solution

A system and method for manufacturing multiple discrete objects from an additively manufactured body of material, which includes a precursor, an extension, and a reference feature, using an automated manufacturing device that generates a computer model for machining, allowing for efficient production and precise control of object geometry.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If subtractive manufacturing processes are used to manufacture multiple discrete objects from a single body of material, then manufacturing precision can be maintained, but labor intensity increases and productivity decreases due to repeated loading and unloading operations

Engineering Contradiction:

Improvemachining precisionVSAvoidproduction efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The single body of material is segmented into multiple discrete objects through additive manufacturing, where each object is built as a separate component. This allows parallel processing and eliminates the need to machine multiple objects from one block, thereby maintaining precision while improving productivity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The discrete objects are preliminarily formed through additive manufacturing before final machining operations. This preliminary shaping reduces the amount of material removal required and minimizes setup time, allowing faster production while maintaining machining precision.

Inventive Principle:

Principle #10Preliminary action

2Adaptability or versatility

If traditional subtractive manufacturing is used, then geometric flexibility is limited by machining constraints, but automation potential is reduced due to manual loading and unloading requirements

Engineering Contradiction:

Improvegeometric flexibilityVSAvoidautomation capability

Core Design Contradiction:

Adaptability or versatilityVSExtent of automation

Solution Approach 1:

Instead of starting with a block and removing material (traditional subtractive approach), the process is inverted by additively building objects layer by layer according to digital models. This enables complex geometries that would be difficult or impossible to machine, while the digital nature of the process enables full automation.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

Manual mechanical operations of loading and unloading material blocks are replaced by digital file transfer and automated additive manufacturing processes. The physical handling of large material blocks is eliminated in favor of digital modeling and automated layer-by-layer construction.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS11640156B2Methods of manufacturing a plurality of discrete objects from a body of material created by additive manufacturing

Publication Date: 2023.05.02 PROTO LABS INC

AI summary

A system for manufacturing a discrete object from an additively manufactured body of material including a precursor to a discrete object and at least a reference feature is disclosed. The system includes an automated manufacturing device, the automated manufacturing device including at least a controller configured to receive a graphical representation of precursor to a discrete object, receive a graphical representation of at least a reference feature on the precursor to the discrete object, and generate a computer model of the body of material, wherein the computer model of the body of material includes the graphical representation of the precursor to the discrete object and the graphical representation of the at least a reference feature.